Display device with organic insulating film having recess and projection

ABSTRACT

According to one embodiment, the organic insulating film and the alignment film are provided on the first substrate. The alignment film is located between the liquid crystal layer and the organic insulating film and contacts the liquid crystal layer. The organic insulating film has a restricting portion on an inner side from the sealant and on an outer side from the display area. The restricting portion includes a recess and a projection extending in predetermined directions. The alignment film is formed on the restricting portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2017-017589, filed Feb. 2, 2017, the entire contents of which are incorporated herein by reference.

FIELD

Embodiments described herein relate generally to a display device.

BACKGROUND

A liquid crystal display device in general includes a pair of substrates, a sealant which attaches the substrates to each other, a liquid crystal layer interposed between the substrates, and an alignment film which aligns liquid crystal molecules included in the liquid crystal layer. If a frame area surrounding a display area is sufficiently broad, the alignment film will be formed on the inner side from the sealant. In the recent liquid crystal display device in which the frame is narrowed, the alignment film may be formed in a location overlapping the sealant or even on the outer side from the sealant.

Embodiments aim to provide a display device which can display a high-quality image.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic plan view of the structure of a display device common in the embodiments.

FIG. 2 is a sectional view of the structure of a display area shown in FIG. 1.

FIG. 3 is a sectional view of the structure of an edge of a first substrate according to the first embodiment.

FIG. 4 is an enlarged sectional view of a regulating portion shown in FIG. 3.

FIG. 5 is a sectional view of a comparative example of the first embodiment shown in FIG. 3.

FIG. 6 is a sectional view of the structure of an edge of a first substrate according to the second embodiment.

DETAILED DESCRIPTION

In general, according to one embodiment, a display device includes a first substrate, a second substrate, a sealant, a liquid crystal layer, an organic insulating film and an alignment film. The second substrate is opposed to the first substrate. The sealant attaches the first substrate and the second substrate to each other. The liquid crystal layer is arranged between the first substrate and the second substrate. The organic insulating film and the alignment film are provided on the first substrate. The alignment film is located between the liquid crystal layer and the organic insulating film and contacts the liquid crystal layer. The first substrate and the second substrate have a display area which displays an image. The organic insulating film has a restricting portion on an inner side from the sealant and on an outer side from the display area. The restricting portion includes a recess and a projection extending in predetermined directions. The alignment film is formed on the restricting portion.

Embodiments will be described hereinafter with reference to the accompanying drawings. Incidentally, the disclosure is merely an example, and proper changes within the spirit of the invention, which are easily conceivable by a skilled person, are included in the scope of the invention as a matter of course. In addition, in some cases, in order to make the description clearer, the widths, thicknesses, shapes, and the like of the respective parts are schematically illustrated in the drawings, compared to the actual modes. However, the schematic illustration is merely an example, and adds no restrictions to the interpretation of the invention. Besides, in the specification and drawings, the structural elements having functions, which are identical or similar to the functions of the structural elements described in connection with preceding drawings, are denoted by like reference numerals, and an overlapping detailed description is omitted unless otherwise necessary.

Further, in this specification, expressions such as “α includes A, B or C”, “α includes any one of A, B and C” and “α is selected from a group consisting of A, B and C” do not exclude a case where α includes combinations of A, B and C unless otherwise specified. Still further, these expressions do not exclude a case where α includes other elements.

A display device DSP, which is a liquid crystal display device, will be disclosed as an example of the display device in the following description. The display device DSP can be used in various devices such as smartphones, tablet computers, mobile phones, personal computers, television receivers, in-vehicle devices, game consoles and wearable devices. The display device DSP has the function of operating in a low frequency driving mode of reducing circuit consumption power under circumstances where low power consumption is valued highly.

Firstly, the structure common in the embodiments will be described with reference to FIGS. 1 and 2. FIG. 1 is a schematic plan view of the structure of the display device DSP. The display device DSP includes a display panel (liquid crystal cell) PNL and an illumination device (backlight) BL which emits light to the display panel PNL, for example. The display panel PNL may be a reflective display panel which displays an image by selectively reflecting light entering the display surface of the display panel PNL. If the display panel PNL is a reflective display panel, the illumination device BL may be omitted.

In the following description, a view from the display surface to the back surface of the display panel PNL as shown in FIG. 1 will be defined as planar view. Further, a first direction X, a second direction Y and a third direction Z will be defined as shown in FIG. 1. The first direction X is a direction along the short sides of the display panel PNL, for example. The second direction Y is a direction along the long sides of the display panel PNL, for example. The third direction Z is the thickness direction of the display panel PNL, for example. In the example shown in FIG. 1, the first, second and third directions X, Y and Z perpendicularly cross each other. The first, second and third directions X, Y and Z may cross each other at another angle.

The display panel PNL includes a first substrate (array substrate) SUB1, a second substrate (counter-substrate) SUB2, a sealant 3 and a liquid crystal layer LC. The second substrate SUB2 is opposed to the first substrate SUB1 in the third direction Z. The first substrate SUB1 is larger than the second substrate SUB2 in the second direction Y and has a terminal area NDAt exposed from the second substrate SUB2.

Further, the first substrate SUB1 has first, second, third and fourth sides E1, E2, E3 and E4. For example, the first and third sides E1 and E3 are the short sides in the first direction X, and the second and fourth sides E2 and E4 are the long sides in the second direction Y.

The sealant 3 is formed of an organic material such as acrylic resin or epoxy resin. Further, the sealant 3 corresponds to a portion shown by rising diagonal lines shown in FIG. 1 and attaches the first substrate SUB1 and the second substrate SUB2 to each other. The liquid crystal layer LC is sealed on the inner side from the sealant 3 between the second substrate SUB2 and the first substrate SUB1.

Further, the display panel PNL has a display area DA which displays an image, and a non-display area (frame area) NDA which surrounds the display area DA. A plurality of sub-pixels SPX are arranged in an m-by-n matrix in the display area DA. For example, a pixel PX which can perform color display can be formed of the combination of three sub-pixels SPX corresponding to red (R), green (G) and blue (B). The pixel PX is not limited to this example but may include a sub-pixel SPX corresponding to another color such as white or may include sub-pixels SPX corresponding to the same color.

The non-display area NDA includes first, second, third and fourth non-display areas NDA1, NDA2, NDA3 and NDA4. The first non-display area NDA1 is located between the display area DA and the first side E1. Similarly, the second non-display area NDA2 is located between the display area DA and the second side E2. The third non-display area NDA3 is located between the display area DA and the third side E3. The fourth non-display area NDA4 is located between the display area DA and the fourth side E4. The first non-display area NDA1 includes the terminal area NDAt.

Further, the display device DSP includes a control module CTR, a scan driver GD and an image driver SD. In the example shown in FIG. 1, the display device DSP includes two scan drivers GD (GD1 and GD2). One of the two scan drivers GD1 and GD2 may be omitted.

The scan driver GD1 is formed on the first substrate SUB1 in the second non-display area NDA2. Similarly, the scan driver GD2 is formed on the first substrate SUB1 in the fourth non-display area NDA4. The scan drivers GD1 and GD2 and the image driver SD are examples of the driver circuit for image display, and can be formed together with a switching element SW of the sub-pixel SPX which will be described later, for example, in the same manufacturing process.

The control module CTR is provided in the terminal area NDAt, for example. The image driver SD is formed on the inner side from the terminal area NDAt in the first non-display area NDA1, for example. The image driver SD in the form of an IC chip may be provided on the first substrate SUB1 instead. The image driver SD may be provided in the control module CTR. The control module CTR and the image driver SD may be provided on an external circuit board connected to the display panel PNL.

Further, the display panel PNL includes a plurality of scanning signal lines GL (GL1, GL2, GL3, GL4, . . . , GLm+1) and a plurality of image signal lines SL (SL1, SL2, SL3, SL4, . . . , SLn+1) crossing the scanning signal lines GL in the display area DA. Still further, the display panel PNL includes a trap power supply line GLt in the non-display area. The trap power supply line GLt is arranged around the display area DA and is connected to the control module CTR.

The scanning lines GL extend in the first direction X and are arranged in the second direction Y. The scanning lines GL are connected to the scan drivers GD. In the example shown in FIG. 1, the odd-numbered scanning lines GL1, G13, . . . , GLm−1 of the scanning signal lines GL are connected to the scan driver GD1, and the even-numbered scanning signal lines GL2, GL4, . . . , GLm of the scanning signal lines GL are connected to the scan driver GD2. The scan drivers GD1 and GD2 supply a scanning signal to the corresponding scanning signal lines GL.

The image signal lines SL extend in the second direction Y and are arranged in the first direction X. The image signal lines SL are connected to the image driver SD. The image driver SD supplies an image signal to the image signal lines SL.

The sub-pixels SPX are areas enclosed with the scanning signal lines GL and the imaging signal lines SL. Each of the sub-pixels SPX includes the switching element SW, a pixel electrode PE and a common electrode CE. The switching element SW is formed of a thin-film transistor (TFT), for example, and is electrically connected to the scanning signal line GL, the image signal line SL and the pixel electrode PE. The common electrode CE is formed over the sub-pixels SPX. The pixel electrode PE is connected to the switching element SW and is opposed to the common electrode CE.

When a scanning signal is supplied to the scanning signal line GL corresponding to a switching element SW, the image signal line SL and the pixel electrode PE corresponding to this switching element SW are electrically connected to each other, and an image signal of the image signal line SL is supplied to the pixel electrode PE. The pixel electrode PE forms an electric field between the pixel electrode PE and the common electrode CE and changes alignment of the liquid crystal molecules of the liquid crystal layer LC. Storage capacitance CS is formed between the common electrode CE and the pixel electrode PE, for example.

The control module CTR controls the operations of the scan drivers GD and the image driver SD. Further, the control module CTR controls the operation of the illumination device BL. Still further, the control module CTR applies a common voltage to the common electrode CE and applies a trap voltage having a potential lower or higher than the common voltage to the trap power supply line GLt. The control module CTR may be formed on an external circuit board connected to the terminal area NDAt and may control the respective members from the external circuit board.

Further, the control module CTR not only has a normal driving function but also has a low frequency driving function of reducing drive power. The low frequency driving is a driving mode of setting the frame frequency of the display device DSP to a frame frequency lower than that of a normal driving mode (for example, 60 Hz). In the low frequency driving, the frame frequency of the display device DSP is 40 Hz or less and is assumed to be 30 Hz or less or 15 Hz or less, for example. The frame frequency corresponds to the frequency of writing an image signal to the sub-pixel SPX. If the frame frequency is reduced, the frequency of writing an image signal to the sub-pixel SPX is reduced, and the power consumption of the circuits can be reduced, accordingly.

FIG. 2 is a sectional view of the display device DSP in the display area DA in the first direction X. The display panel PNL further includes a first polarizer PL1 and a second polarizer PL2. The first polarizer PL1 is arranged on the back surface side of the display panel PNL between the backlight BL and the display panel PNL. The second polarizer PL2 is arranged on the display surface side of the display panel PNL.

In the example shown in FIG. 2, the display panel PNL has a structure conforming to a display mode of mainly using a lateral electric field substantially parallel to an X-Y plane. The display panel PNL may have a structure conforming to a display mode using a longitudinal electric field perpendicular to the X-Y plane, a display mode using an oblique electric field inclined to the X-Y plane, or a display mode using a combination thereof. The display panel PNL of the display mode using the lateral electric field is suitable for the low frequency driving because the display panel PNL of the display mode using the lateral electric field is excellent in voltage holding properties as compared to that of the display mode using the longitudinal electric field.

As described above, the first substrate SUB1 includes the scanning signal line GL, the image signal line SL, and the switching element SW, the pixel electrode PE, the common electrode CE and the trap power supply line GLt. The first substrate SUB1 further includes a first insulating base 10, a first insulating film 11, a second insulating film 12, a third insulating film 13, a fourth insulating film 14, a fifth insulating film 15 and a first alignment film AL1. The switching element SW includes a semiconductor layer SC and a relay electrode SLr. The trap power supply line GLt is connected to a trap electrode TE. A voltage applied to the trap power supply line GLt is applied to the trap electrode TE.

As shown in FIG. 2, the semiconductor layer SC is formed on the first insulating base 10. Another insulating film may be interposed between the semiconductor layer SC and the first insulating base 10. The first insulating film 11 covers the semiconductor layer SC and the first insulating base 10. The scanning signal line GL and the trap power supply line GLt are formed on the first insulating film 11. The scanning signal line GL and the trap power supply line GLt can be formed in the same manufacturing process. The second insulating film 12 covers the scanning signal line GL, the trap power supply line GLt and the first insulating film 11.

The image signal line SL and the relay electrode (a source electrode or a drain electrode) SLr are formed on the second insulating film 12 and contact the semiconductor layer SC via contact holes CH1 and CH2. The image signal line SL and the relay electrode SLr can be formed in the same manufacturing process. The third insulating film 13 covers the image signal line SL, the relay electrode SLr and the second insulating film 12. The fourth insulating film 14 covers the third insulating film 13. The common electrode CE is formed on the fourth insulating film 14. The fifth insulating film 15 covers the common electrode CE and the fourth insulating film 14. The fifth insulating film 15 functions as an interlayer insulating film which insulates the pixel electrode PE and the common electrode CE from each other.

The pixel electrode PE is formed on the fifth insulating film 15 and contacts the relay electrode SLr via a contact hole CH3. The trap electrode TE is formed on the fifth insulating film 15 and contacts the trap power supply line GLt via a contact hole CH4. The pixel electrode PE and the trap electrode TE are examples of the transparent conductive film and can be formed in the same manufacturing process. The trap electrode TE is an electrode to which a voltage (the same voltage as a gate low voltage which turns off the switching element SW, for example) is applied from the trap power supply line GLt and which holds ions generated from the sealant 3 and the liquid crystal layer LC.

The pixel electrode PE may be formed below the fifth insulating film 15, and the common electrode CE may be formed on the fifth insulating film 15. In that case, the trap electrode TE and the common electrode CE may be formed in the same manufacturing process. The common electrode CE is another example of the transparent conductive film. The first alignment film AL1 covers the pixel electrode PE, the trap electrode TE and the fifth insulating film 15 and contacts the liquid crystal layer LC. The first alignment film AL1 aligns the liquid crystal molecules of the liquid crystal layer LC in a state where a voltage is not applied to the pixel electrode PE.

A translucent and insulating glass base or resin base can be used as the first insulating base 10, for example. The common electrode CE, the pixel electrode PE and the trap electrode TE can be formed of a transparent conductive material such as indium tin oxide (ITO) or indium zinc oxide (IZO). The scanning signal line GL and the trap power supply line GLt, the image signal line SL and the relay electrode SLr are metal lines having a single layer structure or a stacked layer structure, for example.

The first alignment film AL1 can formed by applying polyimide resin, etc., by ink-jet printing, flexographic printing, etc., for example. The first alignment film AL1 may extend outside the sealant 3 (shown in FIG. 3). The first alignment film AL1 has a thickness of 100 nm, for example.

The fourth insulating film 14 is an organic insulating film formed of photosensitive resin such as acrylic resin, for example, and extends to the edges of the first substrate SUB1. The fourth insulating film 14 has the function of leveling unevenness of the switch element SW and is thicker than the first, second, third and fifth insulating films 11, 12, 13 and 15 and the first alignment film AL1. The fourth insulating film 14 may be referred to as an organic leveling film. For example, the thickness of the fourth insulating film 14 should preferably be ten or more times the thickness of the first alignment film AL1. In this way, moisture absorption properties and surface flatness which will be described later can be ensured.

The fourth insulating film 14 is formed by photolithography, for example, and the thickness is adjusted on a portion-to-portion basis by multi-tone processing such as half-tone processing (shown in FIG. 3). A portion of the fourth insulating film 14 which is not subjected to the multi-tone processing has a thickness of 3 μm, for example. A portion of the fourth insulating film 14 which is subjected to the half-tone processing has a thickness of 1.5 μm, for example.

The first, second, third and fifth insulating films 11, 12, 13 and 15 are an inorganic insulating film of silicon oxide, silicon nitride, alumina, etc. The first, second, third and fifth insulating films 11, 12, 13 and 15 are impervious to water. On the other hand, the first alignment film AL1 and the fourth insulating film 14 formed of an organic material is slightly pervious to water.

The second substrate SUB2 includes a second insulating base 20, a light-shielding layer (black matrix) 21, a color filter layer 22, an overcoat layer 23 and a second alignment film AL2. The second insulating base 20 can be formed of the same material as that of the first insulating base 10. The second alignment film AL2 can be formed of the same material as that of the first alignment film AL1.

As shown in FIG. 2, the light-shielding layer 21 is formed below the second insulating base 20. The color filter layer 22 covers the light-shielding layer 21 and the second insulating base 20. The light-shielding layer 21 is located in the non-display area NDA in planar view. Further, the light-shielding layer 21 is located directly above metal lines such as the scanning signal line GL, the image signal line SL, the relay electrode SLr, etc., and the sub-pixels PSX are partitioned by the light-shielding layer 21 in the display area DA. The color filter layer 22 is opposed to the pixel electrode PE and partially overlaps the light-shielding layer 21.

The color filter layer 22 includes a red filter layer, a green filter layer, a blue filter layer, etc., arranged in accordance with the sub-pixels SPX. The overcoat layer 23 covers the color filter layer 22. The second alignment film AL2 covers the overcoat layer 23 and contacts the liquid crystal layer LC.

[First Embodiment]

Next, the display device DSP of the first embodiment will be described with reference to FIGS. 3 to 5. FIG. 3 is a sectional view of the structure of the display device DSP in the fourth non-display area NDA4 of the first embodiment. The cross-section structures in the first, second and third non-display areas NDA1, NDA2 and NDA3 have substantially the same shape and function as those of the cross-section structure in the fourth non-display area NDA4. Therefore, the fourth non-display area NDA4 will be described as a representative example, and redundant descriptions of the first, second and third non-display areas NDA1, NDA2 and NDA3 will be omitted.

One of the features of the display device DSP of the present embodiment is that a regulating portion 60 (a recess 61 and a projection 62) on the inner side from the sealant 3 and on the outer side from the display area DA.

As shown in FIG. 3, the fourth insulating film 14 has a groove 40 formed in such a manner as to surround the display area DA. The groove 40 can be formed by removing the fourth insulating film 14 by full-tone processing, for example. The fourth insulating film 14 is divided into a peripheral portion 41 and a central portion 42 by the groove 40. An upper surface 41A and a side surface 41N of the peripheral portion 41 are covered with the fifth insulating film 15 which is impervious to water. The fifth insulating film 15, which covers the peripheral portion 41, and the groove 40 cut out moisture entering from the peripheral portion 41 and prevent moisture from entering the central portion 42.

The display device DSP further includes a spacer PS1 and a spacer PS2 for regulating the gap between the first substrate SUB1 and the second substrate SUB2. The spacer PS1 has the shape of a frame, for example, and is arranged on the upper surface 41A of the peripheral portion 41 of the fourth insulating film 14. The spacer PS1 prevents the fluidized sealant 3 from spreading on the outer side from the spacer PS1 when the first substrate SUB1 and the second substrate SUB2 are attached to each other by the sealant 3.

The spacer PS2 is formed in the sealant 3 on the second substrate SUB2 and projects toward the first substrate SUB1 in a column-like manner. The color filter layer 22 in the non-display area NDA overlaps the spacers PS1 and PS2 in planar view. The color filter layer 22 regulates the gap between the first substrate SUB1 and the second substrate SUB2 together with the spacer PS1 and the spacer PS2.

As shown in FIG. 3, the display device DSP includes a transparent conductive film TC formed in the non-display area NDA. An example of the transparent conductive film TC formed in the non-display area NDA is the trap electrode TE which holds ions generated form the sealant 3 and the liquid crystal layer LC. The transparent conductive film TC may serve as an electric filed shield which mitigates the impact of an electromagnetic force from the outside, etc.

The transparent conductive film TC overlaps the scan driver GD2 in planar view, for example. In this way, the impact of an electric field from the scan driver GD2 on the liquid crystal layer LC and the impact of an electromagnetic force from the outside on the scan driver GD2 can be prevented. Other circuits such as the scan driver GD1 and the image driver SD may also overlap the transparent conductive film TC in planar view.

Further, the transparent conductive film TC may be formed for the purpose of improving adhesiveness. The fifth insulating film 15 has low adhesiveness with respect to the sealant 3 and the fourth alignment film AL1 as compared to the transparent conductive film TC. If the transparent conductive film TC is formed on the fifth insulating film 15, the adhesiveness with respect to them can be improved. In the example shown in FIG. 3, the transparent conductive film TC is formed in such a manner as to overlap the sealant in planar view. The transparent conductive film TC can be formed together with one of the pixel electrode PE and the common electrode CE, which are transparent conductive films formed in the display area DA, in the same manufacturing process.

The transparent conductive film TC has the shape of a ring surrounding the display area DA, for example. The transparent conductive film TC may not be formed in one or some of the first, second, third and fourth areas NDA1, NDA2, NDA3 and NDA4. Further, the transparent conductive film TC may be discontinuous in the first, second, third and fourth non-display areas NDA1, NDA2, NDA3 and NDA4.

Attention is focused on the vicinity of the boundary between the liquid crystal layer LC and the sealant, and an area on the inner side from the sealant 3 and on the outer side from the display area DA is assumed to be a boundary area NDAin. The display device DSP of the present embodiment has the regulating portion 60 in the boundary area NDAin. The width of the boundary area NDAin is 50 μm, for example. The width of the regulating portion 60 is 35 μm, for example.

The regulating portion 60 includes the recess 61 and the projection 62. Although three recesses 61 and two projections 62 between the adjacent recesses 61 are provided in the example shown in FIG. 3, the number of the recesses 61 and the number of the projections 62 included in the regulating portion 60 are not limited to these numbers. Further, the regulating portion 60 may include either one of the recess 61 and the projection 62.

The recess 61 extends along the sides E1, E2, E3 and E4 and is recessed from the surface 14A of the fourth insulating film 14, for example. The first direction X along the sides E1 and E3 and the second direction Y along the sides E2 and E4 are examples of the extension directions of the recess 61 and the projection 62. The recess 61 can be formed by multi-tone processing such as half-tone processing, for example. A portion 14B of the fourth insulating film 14 in the thickness direction which is not removed by the multi-tone processing remains between the bottom of the recess 61 (a center Xd which will be described later) and the third insulating film 13.

The projection 62 is formed between the adjacent recesses 61, for example. In the example shown in FIG. 3, the top of the projection 62 is located at the same height as that of the surface 14A of the fourth insulating film 14, and the projection 62 is projecting from the perspective of the recess 61. The top of the projection 62 may be lower than the surface 14A or may be higher than the surface 14A. The projection 61 higher than the surface 14A can be formed together with the spacer PS1 in the same manufacturing process, for example.

In the example shown in FIG. 3, the top of the projection 62 is covered with the transparent conductive film TC. At the time of printing the composition of the first alignment film AL1, the composition of the first alignment film AL1 falls from the projection 62 to the recess 61. As a result, the first alignment film AL1 is divided in the regulating portion 60. The wettability of the transparent conductive film TC with respect to the composition of the first alignment film AL1 is lower than that of the fourth insulating film 14 with respect to the composition of the first alignment film AL1.

When the projection 62 is covered with the transparent conductive film TC, the transparent conductive film TC sheds the composition of the first alignment film AL1, and therefore the first alignment film AL1 will be more clearly divided. The transparent conductive film TC is not an essential structure in the regulating portion 60, and the projection 62 and the recess 61 may not be covered with the transparent conductive film TC.

FIG. 4 is an enlarged sectional view of the regulating portion 60. The transparent conductive film TC, the scan driver GD2, etc., are omitted in FIG. 4. The tops of projections 62A, 62B and 62C shown in FIG. 4 are referred to as tops Xa, Xb and Xc, respectively. Further, the distance between the top Xa of the projection 61A and the top Xb of the projection 62B which are adjacent to each other is referred to as a distance W1, and the distance between the top Xb of the projection 62B and the top Xc of the projection 62C which are adjacent to each other is referred to as a distance W2.

In the example shown in FIG. 4, a point Xd which divides the distance between the top Xa of the projection 62A and the top Xb of the projection 62B in half is defined as the center of a recess 61D shown in FIG. 4. Further, a point Xe which divides the distance between the top Xb of the projection 62B and the center Xd of the recess 61D in half is defined as the boundary between the projection 62B and the recess 61D.

Here, in the example shown in FIG. 4, the width of the recess 61D is a half of the distance W1 between the tops Xa and Xb of the projections 62A and 62B adjacent to the recess 61D. The width of the projection 62B is the sum of a quarter of the distance W1 between the tops Xa and Xb and a quarter of the distance W2 between the tops Xb and Xc. If the projections 62 are only the projections 62A and 62B, the width of the projection 62B is a half of the distance W1 between the tops Xa and Xb of the projections 62A and 62B.

In the example shown in FIG. 4, the width (½)·W1 of the recess 61D is 7 μm, for example. The width (¼)·W1+(¼)·W2 of the projection 62B is substantially equivalent to the width of the recess 61 and is 7 μm, for example.

The height of the top Xa of the projection 62A shown in FIG. 4 is the same as the height of the surface 14A of the fourth insulating film 14. A thickness D1 of the projection 62A at the top Xa is the same as the thickness of the fourth insulating film 14 which is not subjected to the multi-tone processing, and is assumed to be 3 μm, for example. A depth D2 of the recess 61D in the center Xd is 1.5 μm, for example. As shown in FIG. 4, the third insulating film 13 in the recess 61D is covered with the fourth insulating film 14 having a thickness of 1.5 μm.

If the composition of the first alignment film AL1 is applied to the regulating portion 60, the composition of the first alignment film AL1 applied to the projection 62 falls to the recess 62. The portion of the first alignment film AL1 in the projection 62 becomes thinner than the other portion of the first alignment film AL1, and the first alignment film AL1 is divided by the regulating portion 60. In the example shown in FIG. 4, a thickness T1 of the first alignment film AL1 at the top Xa of the projection 62 is 10 nm, for example. A thickness T2 of the first alignment film AL1 in the center Xd of the recess 61 is 100 nm, for example.

In the display device DSP of the present embodiment having the above-described structure, the first alignment film AL1 is divided by the regulating portion 60. FIG. 5 is a sectional view of a comparative example of the present embodiment. If the regulating portion 60 is not formed as in the case of the comparative example shown in FIG. 5, and when the display device DSP is left in hot and humid conditions for a long time, external moisture entering from the sealant 3 and the first alignment film AL1 may go beyond the groove 40 and reach the display area DA.

In the display area DA, if the volume resistivity of the liquid crystal layer LC is reduced by the entering of moisture, the electric charge of the liquid crystal layer LC flows to the first alignment film AL1 and this promotes the voltage reduction of the liquid crystal layer LC. In association with this voltage reduction, the brightness of an image displayed in the display area DA decreases in cycles, that is, flicker occurs. The flicker cycle is long in the above-described low frequency driving. Further, since the rewrite cycle of the voltage of the pixel electrode PE is long, the voltage reduction of the liquid crystal layer LC is likely to be large. Therefore, flicker tends to be more noticeable in the low frequency driving mode as compared to the normal driving mode.

On the other hand, in the display device of the present embodiment shown in FIG. 3, the first alignment film AL1 in the display area DA and the edge of the first alignment film AL1 facing the outside are divided by the regulating portion 60. Since the external moisture entering from the edge of the first alignment film AL1 can be cut out, the moisture absorption of the first alignment film AL1 in the display area DA can be prevented, and flicker can be prevented, accordingly.

Meanwhile, the sealant 3 is formed of an organic material and is thus slightly pervious to water. Since the liquid crystal molecules of the liquid crystal layer LC is hardly pervious to water, the moisture entering the sealant 3 is absorbed by the first alignment film AL1. In a case where the sealant 3 is located on the inner side (the display area DA side) from the regulating portion 60, even if all the moisture entering from the first alignment film AL1 is cut out, the volume resistivity of the liquid crystal layer LC and the first alignment film AL1 in the display area DA may be gradually reduced by the moisture entering through the sealant 3.

On the other hand, the moisture path from the edge of the display panel PNL to the display area DA can be cut out in the boundary area NDAin located on the inner side from the sealant 3 and on the outer side from the display area DA. Therefore, the moisture absorption of the first alignment film AL1 in the display area DA can be prevented regardless of the material of the sealant 3.

The recess 61 of the regulating portion 60 is formed not by the full-tone processing but by the half-tone processing. Therefore, even if the regulating portion 60 is formed directly above the drive circuits (the scan drivers GD1 and GD2, etc.), the third insulating film 13 will not be exposed. If moisture ever enters from the recess 61, the third insulating film 13 is covered with the portion 14B of the fourth insulating film 14 in the thickness direction, and the drive circuits can limit the impact of the moisture. Since the drive circuits and the regulating portion 60 can be arranged in such a manner as to overlap each other in the narrow non-display area NDA, the design flexibility of the layout of the regulating portion 60 and the drive circuits can be increased. As a result, the frame of the display panel PNL can be narrowed.

The present embodiment can provide various other advantages.

[Second Embodiment]

Next, the display device of the second embodiment will be described. A structure having the same or a similar function as the structure described in the first embodiment will be denoted by the same reference number and will be referred to the corresponding description in the first embodiment, and detailed description thereof will be omitted. Further, structures other than those described below are the same as those of the first embodiment. FIG. 6 is a sectional view of the display device DSP of the second embodiment. As shown in FIG. 6, the display device DSP of the second embodiment differs from the first embodiment in including a lower bypass area BA1.

In the second embodiment, the fifth insulating film 15 is formed between the first alignment film AL1 and the fourth insulating film 14 in the display area DA. On the other hand, the fifth insulating film 15 is not formed between the first alignment film AL1 and the fourth insulating film 14 in the lower bypass area BA1 located in the non-display area NDA.

The second embodiment further includes an upper bypass area BA2 in the non-display area NDA. In the upper bypass area BA2, the transparent conductive film TC is not formed between the first alignment film AL1 and the fourth insulating film 14. Therefore, the first alignment film AL1 and the fourth insulating film 14 directly contact each other in an overlapping area DBA in which the lower bypass area BA1 and the upper bypass area BA2 overlap each other in planar view.

In the example shown in FIG. 6, the overlapping area DBA is located on the inner side (on the display area DA side) from the groove 40 which cuts out moisture, and has the shape of a ring which surrounds the display area DA. The overlapping area DBA does not necessarily surround the display area DA completely and may be partially discontinuous. The overlapping area DBA should preferably include an inner overlapping area DBAin. The inner overlapping area DBAin is an area in which the boundary area NDAin and the overlapping area DBA overlap each other in planar view.

In the second embodiment, neither the fifth insulating film 15 nor the transparent conductive film TC is formed in the overlapping area DBA. The first alignment film AL1 contacts the fourth insulating film 14 which is an organic insulating film. According to the second embodiment, moisture entering the first alignment film AL1 can be distributed to the fourth insulating film 14 through the overlapping area DBA, and therefore the electrical resistivity of the first alignment film AL1 can be prevented from being reduced.

If the first alignment film AL1 is formed of polyimide resin and the fourth insulating film 14 is formed of acrylic resin, the first alignment film AL1 and the fourth insulating film 14 can contain about the same amount of moisture per unit volume. The fourth insulating film 14 according to the present embodiment is ten or more times thicker than the first alignment film AL1 and can sufficiently absorb the moisture of the first alignment film AL1. In the example shown in FIG. 6, the fourth insulating film 14 is 30 times thicker than the first alignment film AL1.

Further, the display device DSP of the second embodiment has the inner side overlapping area DBAin. The inner overlapping area DBAin overlaps the boundary area NDAin in which the moisture entering the sealant 3 is absorbed into the first alignment film AL1, and can dissipate the moisture from the sealant 3 into the fourth insulating film 14. The fourth insulating film 14 formed of an organic insulating film is superior to the fifth insulating film 15 formed of an inorganic insulating film in adhesiveness with respect to the first alignment film AL1. According to the second embodiment, the adhesive strength between the first alignment film AL1 and the fourth insulating film 14 in the vicinity of the sealant 3 can be improved.

While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.

For example, the first polarizer PL1 may be omitted by using the illumination device BL which emits polarized light. For example, the color filter layer 22 may be formed not on the second substrate SUB2 but on the first substrate SUB1. Although the recess 61 is formed as a recess extending along the sides E1, E2, E3 and E4 and the projection 62 is formed as a projection extending along the sides E1, E2, E3 and E4, the recess 61 and the projection 62 may be formed discontinuously instead. 

What is claimed is:
 1. A display device comprising: a first substrate; a second substrate facing the first substrate; a sealant which attaches the first substrate and the second substrate to each other; a liquid crystal layer arranged between the first substrate and the second substrate; an organic insulating film provided on the first substrate; and an alignment film provided on the first substrate and contacting the liquid crystal layer, wherein the first substrate and the second substrate have a display area which displays an image, a plurality of sub-pixels are arranged in the display area, the alignment film is located between the liquid crystal layer and the organic insulating film, the organic insulating film has a restricting portion on an outer side from the display area, and the restricting portion includes a recess and a projection extending in predetermined directions, the alignment film is divided into a first alignment film and a second alignment film by the projection of the restricting portion, the first alignment film overlaps the display area, and the second alignment film is located between the projection and an edge of the first substrate, and the second alignment film is separated from the first alignment film, and the alignment film is not formed on the projection.
 2. The display device of claim 1, wherein the projection has a width of 10 μm or less.
 3. The display device of claim 1, wherein the organic insulating film is also provided in a bottom portion of the recess.
 4. The display device of claim 1, further comprising a transparent conductive film contacting the organic insulating film, wherein the transparent conductive film is provided between the sealant and the organic film and on an inner side from the sealant, and is not provided on the outer side from a regulating portion.
 5. The display device of claim 3, further comprising a transparent conductive film contacting the organic insulating film, wherein the transparent conductive film is provided between the sealant and the organic insulating film and on an inner side from the sealant, and is not provided on the outer side from the restricting portion.
 6. The display device of claim 4, wherein the first substrate comprises an insulating base and a drive circuit for displaying an image in the display area, and the drive circuit is provided between the insulating base and the regulating portion, and overlaps the regulating portion in planar view.
 7. The display device of claim 5, wherein the first substrate comprises an insulating base and a drive circuit for displaying an image in the display area, and the drive circuit is provided between the insulating base and a regulating portion, and overlaps the regulating portion in planar view.
 8. The display device of claim 1, wherein the alignment film contacts the organic insulating film on an inner side from the sealant and on the outer side from the display area.
 9. The display device of claim 3, wherein the alignment film contacts the organic insulating film on an inner side from the sealant and on the outer side from the display area.
 10. The display device of claim 4, wherein the alignment film contacts the organic insulating film on an inner side from the sealant and on the outer side from the display area.
 11. The display device of claim 5, wherein the alignment film contacts the organic insulating film on an inner side from the sealant and on the outer side from the display area.
 12. The display device of claim 2, wherein the alignment film contacts the organic insulating film on an inner side from the sealant and on the outer side from the display area.
 13. The display device of claim 3, wherein the alignment film contacts the organic insulating film on an inner side from the sealant and on the outer side from the display area.
 14. The display device of claim 6, wherein the alignment film contacts the organic insulating film on an inner side from the sealant and on the outer side from the display area.
 15. The display device of claim 7, wherein the alignment film contacts the organic insulating film on an inner side from the sealant and on the outer side from the display area.
 16. The display device of claim 1, wherein a regulating portion extends in an extension direction of the sealant.
 17. The display device of claim 3, wherein a regulating portion extends in an extension direction of the sealant.
 18. The display device of claim 1, wherein a frame frequency of the image displayed in the display area is 40 Hz or less. 